Battery powered cordless cleaning system

ABSTRACT

A cordless, battery-powered system of cleaning products. The system of cleaning products includes devices such as upright vacuums (e.g., a stick vacuum, a lightweight upright vacuum, etc.), a hand-held vacuum, a carpet-cleaner, a canister vacuum, and the like. Each of the devices is powered by a battery pack which is interchangeable among the devices. The battery pack includes a combination of hardware and software for connecting to, identifying, and communicating with the cleaning products to ensure that each of the products receives the power necessary to ensure optimal performance.

RELATED APPLICATIONS

This application is a division of previously-filed, co-pending U.S.patent application Ser. No. 12/580,878, filed Oct. 16, 2009, which is acontinuation-in-part of U.S. patent application Ser. No. 12/405,033,filed Mar. 16, 2009, which claims the benefit of U.S. Provisional PatentApplication No. 61/036,720, filed Mar. 14, 2008, the entire contents ofall of which are hereby incorporated by reference. U.S. patentapplication Ser. No. 12/580,878 is also a continuation-in-part of U.S.patent application No. 29/326,368, filed Oct. 16, 2008, now U.S. Pat.No. D652377, U.S. patent application No. 29/326,362, filed Oct. 16,2008, now U.S. Pat. No. D615616, and U.S. patent application No.29/326,364, filed Oct. 16, 2008, now abandoned, the entire contents ofall of which are hereby incorporated by reference. U.S. patentapplication Ser. No. 12/580,878 also claims the benefit ofpreviously-filed co-pending U.S. Provisional Patent Application No.61/105,891, filed Oct. 16, 2008, U.S. Provisional Patent Application No.61/105,899, filed Oct. 16, 2008, and U.S. Provisional Patent ApplicationNo. 61/105,896, filed Oct. 16, 2008, the entire contents of all of whichare hereby incorporated by reference.

BACKGROUND

Consumer devices, such as suction force cleaners having both a suctionmotor and impeller or fan assembly (e.g., vacuum cleaners), have beenlimited almost exclusively to corded, AC powered devices. The powerrequired to operate such devices is prohibitive to the development of acordless vacuum cleaner that is able to provide portability,functionality, and adequate suction force. Attempts have been made toincorporate battery packs into vacuum cleaners. Although some of theseattempts have succeeded in reducing vacuum cleaners' dependence on ACpower, they have been unable to provide a solution that is adequateamong multiple types of devices.

SUMMARY

Cleaning systems include a wide range of products designed to meet awide variety of cleaning needs, and cleaning often requires the use ofmultiple devices to sufficiently clean a room or space. Large and smallcleaning devices alike suffer from a lack of portability and operationalcongruence. For example, the multiple devices used for cleaning ofteninclude an upright suction force cleaner for cleaning large surfaceareas with a significant amount of debris and a smaller, hand-heldcleaning device for cleaning smaller or confined areas. As anotherexample, a canister vacuum is used in combination with an uprightcleaning device or a hand-held vacuum. No matter the combination ofdevices being used, the efficiency, portability, and compatibilityassociated with using multiple devices is hindered by, among otherthings, the different power requirements of each device. For example, ahand vacuum, which is typically a battery powered device, requires itsown charger or replaceable batteries, and an upright vacuum, which istypically a corded device, requires a user to be within power cord-rangeof a power outlet.

Embodiments of the invention provide a cordless cleaning system thatincludes devices such as a stick vacuum, a lightweight upright vacuum, ahand-held vacuum, a carpet-cleaner, a canister vacuum, and the like.Each of the devices is capable of being powered by a single battery packwhich is interchangeable among the devices. For example, the batterypack is initially inserted into the stick vacuum, and is then removedand inserted into the hand-held vacuum. The battery pack includes acombination of hardware and software for identifying and communicatingwith each of the devices to ensure that each of the devices receives thepower necessary to ensure optimal performance. The battery pack alsoincludes additional control electronics which maximize the charge-lifeof the battery pack, allow charging parameters and characteristics to bemodified, and ensure an accurate charge determination for both thebattery pack as a whole and the individual cells within the batterypack.

In one embodiment, the battery pack is configured to enter a “sleep”mode when not inserted in a battery charger or other valid device (e.g.,during a storage period). When in the sleep mode, power consumption ofthe battery pack is minimized to maintain cell charge. During the sleepmode, the battery pack removes power from its power terminals, and abattery pack control circuit enters a low or reduced power mode toprolong the life of the battery. The battery pack is also configured toenter a “wake” mode when the battery pack is inserted into an electricaldevice, and a voltage (e.g., a logical high voltage) is applied to aserial communication terminal of the battery pack. If no voltage isapplied to the serial communication terminal, the battery pack isconfigured to wake up from the sleep mode once every 1-2 hours toperform a voltage level check and a battery cell temperature check.

In another embodiment, the battery pack is configured to communicatewith devices (e.g., a battery charger, a configuration device, etc.) toadjust or change the charge and/or discharge parameters of the batterypack. Additionally or alternatively, a battery pack controller isconfigured to store cell-specific operating parameters in a memory, andis capable of adjusting or changing the operating parameters accordingto information received from the devices.

In yet another embodiment, the battery pack is configured to communicatewith a device (e.g., a battery charger, a cleaning device, etc.) whichincludes a fuel gauge that displays the remaining battery chargecapacity of the battery pack. The battery pack stores cell-specificoperating parameters in a memory and provides information to thedevice's fuel gauge that accurately represents the remaining batterycharge capacity of the battery pack. The information is based on theoperating parameters stored in memory including, among other things,discharge currents, charge currents, and threshold values.

Additionally, the battery pack is operable to provide power to any of aplurality of additional devices. For example, the battery pack iscapable of providing power to any number of devices having differentvoltage and current requirements, such as power tools, test andmeasurement equipment, outdoor power equipment, and vehicles. Powertools include, for example, drills, circular saws, jig saws, band saws,reciprocating saws, screw drivers, angle grinders, straight grinders,hammers, impact wrenches, angle drills, inspection cameras, and thelike. Test and measurement equipment includes digital multimeters, clampmeters, fork meters, wall scanners, IR temperature guns, and the like.Outdoor power equipment includes blowers, chain saws, edgers, hedgetrimmers, lawn mowers, trimmers, and the like.

In one embodiment, the invention provides a cordless cleaning systemthat includes a rechargeable battery pack, a first cordless cleaningdevice, and a second cordless cleaning device. The rechargeable batterypack includes a housing and at least two cells within the housing. Thefirst cordless cleaning device and the second cordless cleaning deviceare operable to removably receive and be powered by the battery pack.The first device is a first type of cleaning device, the second deviceis a second type of cleaning device, and the first type of cleaningdevice is different than the second type of cleaning device. At leastone of the first device and the second device has an upright workingposition.

In another embodiment, the invention provides a cordless vacuum cleaner.The vacuum cleaner includes a nozzle base portion, a body portion, atleast one motor, and a switch. The nozzle base portion includes asuction inlet, and the body portion is operable to receive alithium-based battery pack that is removably coupled to the vacuumcleaner. The at least one motor is powered by the battery pack and isconfigured to provide a suction force at the suction inlet. The batterypack is received in a recess positioned above each of the at least onemotor. The vacuum cleaner is configured to operate in a first mode and asecond mode, and the switch is configured to select the first mode orthe second mode to selectively supply power to each of the at least onemotor.

In yet another embodiment, the invention provides a cordless vacuumcleaner. The vacuum cleaner includes a nozzle base portion, a bodyportion, a junction between the nozzle base portion and the bodyportion, a suction source, and a battery pack interface. The nozzle baseportion includes a suction inlet. The suction source provides a suctionforce at the suction inlet, and the battery pack interface is configuredto receive a removable and rechargeable lithium-based battery pack. Thesuction source is powered by the battery pack, and the battery packinterface is positioned above the suction source. The body portion isalso supportable in a vertical position by the junction between thenozzle base portion and the body portion without external support.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a cordless cleaning system according to an embodimentof the invention.

FIG. 2 is a perspective view of a battery pack according to anembodiment of the invention.

FIG. 3 is another perspective view of the battery pack of FIG. 2.

FIG. 4 is a partial perspective view of the battery pack of FIG. 2.

FIG. 5 is a side view of a lever according to an embodiment of theinvention.

FIG. 6 is another side view of a lever according to an embodiment of theinvention.

FIG. 7 is a side view of the battery pack of FIG. 2 with an externalhousing removed.

FIG. 8 is a perspective view of a latching mechanism according to anembodiment of the invention.

FIG. 9 is a perspective view of the battery pack of FIG. 2 with theexternal housing removed.

FIG. 10 is another perspective view of the battery pack of FIG. 2 withthe external housing removed.

FIG. 11 shows a process for removing the battery pack of FIG. 2 from adevice according to an embodiment of the invention.

FIG. 12 is a perspective view of a battery charger according to anembodiment of the invention.

FIG. 13 is a perspective view of the battery pack of FIG. 2 insertedinto the battery charger of FIG. 12.

FIG. 14 illustrates a charging circuit for a battery charger accordingto an embodiment of the invention.

FIG. 15 illustrates a control circuit and an interface between a batterypack and a device according to an embodiment of the invention.

FIG. 16 illustrates a battery pack controller according to an embodimentof the invention.

FIGS. 17 and 18 show a process for switching a battery pack between a“sleep” mode and a “wake” mode.

FIG. 19 is a perspective view of a cleaning device according to anembodiment of the invention.

FIG. 20 is a front view of the cleaning device of FIG. 19.

FIG. 21 is a side view of the cleaning device of FIG. 19.

FIG. 22 is a top view of the cleaning device of FIG. 19.

FIG. 23 is a bottom view of the cleaning device of FIG. 19.

FIG. 24 is a perspective view of an interface between a handle portionand a body portion of the cleaning device of FIG. 19 according to anembodiment of the invention.

FIG. 25 is a perspective view of a refuse chamber for the cleaningdevice of FIG. 19 according to an embodiment of the invention.

FIG. 26 is a perspective view of an interface between a base portion anda body portion of the cleaning device of FIG. 19 according to anembodiment of the invention.

FIG. 27 is a perspective view of a cleaning device according to anotherembodiment of the invention.

FIG. 28 is a rear view of the cleaning device of FIG. 27.

FIG. 29 is a top view of the cleaning device of FIG. 27.

FIG. 30 is a bottom view of the cleaning device of FIG. 27.

FIGS. 31-39 illustrate devices coupled to the battery charger of FIG. 12according to embodiments of the invention.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways.

Embodiments of the invention described herein relate to a cordless,battery-powered system of electronic devices, such as a system ofcleaning products. The system of cleaning products includes devices suchas upright vacuums (e.g., a stick-type vacuum, a lightweight uprightvacuum, etc.), a hand-held vacuum, a carpet-cleaner, a canister vacuum,a wet/dry floor cleaner, and the like. Each of the devices is powered bya battery pack which is interchangeable among the devices. The batterypack includes a combination of hardware and software for connecting to,identifying, and communicating with each of the devices to ensure thateach of the devices receives the power necessary to ensure optimalperformance. For example, the battery pack includes a latch and a rodfor removably securing the battery pack to the devices. The battery packalso includes control electronics which maximize the charge-life of thebattery pack by operating the battery pack in a “sleep” mode, allowcharging parameters and characteristics to be modified, and ensure anaccurate battery pack charge determination.

FIG. 1 illustrates a cordless cleaning system 10 that includes ahand-held vacuum 15, a stick-type vacuum 20, a bagless upright vacuum25, a battery charger 30, a bagged upright vacuum 35, a carpet cleaner40, and a canister vacuum 45. Each of the devices 15-45 is connectableto and powered by a battery pack 50. The battery pack 50 has, forexample, a nickel-metal hydride (“NiMH”), nickel-cadmium (“NiCd”),lithium-cobalt (“Li—Co”), lithium-manganese (“Li—Mn”), Li—Mn spinel, orother suitable lithium or lithium-based chemistry. The battery pack 50has a nominal voltage rating of 4V, 8V, 12V, 16V, 18V, 20V, 24V, 36V,48V, etc., or any voltage rating therebetween or greater than 48V.Battery cells within the battery pack 50 have capacity ratings of, forexample, 1.2 Ah, 1.3 Ah, 1.4 Ah, 2.0 Ah, 2.4 Ah, 2.6 Ah, 3.0 Ah, etc.The individual cell capacity ratings are combined to produce a totalbattery pack capacity rating, which is based both on the capacityratings of the individual cells and the number of cells in the batterypack 50. In some embodiments, the individual battery cells have energydensities of 0.348 Wh/cm³, although other energy densities are used inother embodiments. The battery pack 50 is able to provide an overallenergy density of, for example, at least 0.084 Wh/cm³.

FIGS. 2-10 illustrate the battery pack 50 in greater detail. The batterypack 50 includes a housing 55 formed of a first half or shell 60 and asecond half or shell 65. The first and second shells 60 and 65 arecoupled to one another using, for example, screws 70 or other suitablefastening devices or materials. A lever 75 is pivotally mounted to thehousing 55, and enables the removal of the battery pack 50 from each ofthe devices in the cordless cleaning system 10. A first end 80 of thelever 75 is pulled to unlatch or to eject the battery pack 50 from adevice. In some embodiments, the first end 80 is formed as a raisedportion adjacent to a recess 85. The raised portion of the first end 80and the recess 85 are sized to receive, for example, a user's finger oranother object to pivot the lever 75.

The lever 75 is pivotally mounted to the housing 55. A push rod 90 (FIG.4) is movably mounted to the housing 55, and is configured to be axiallymoved by the pivoting motion of the lever 75. A latch 95 is extendable,movably mounted to the housing 55, and configured to be moved from afirst position (e.g., a latched position) to a second position (e.g., anunlatched position) by the movement of the push rod 90. While in thelatched position, the latch 95 securely couples the battery pack 50 to adevice. The movement of the latch 95 from the first position to thesecond position allows the battery pack 50 to be removed from a device.In the illustrated embodiments, a single latch is provided. In otherembodiments, additional latches are provided within a battery pack.

As illustrated in FIGS. 5 and 6, the lever 75 pivots about a connectionpoint 100. As the first end 80 of the lever 75 is lifted, a second end105 of the lever 75 is rotated downward and brought into contact withthe push rod 90. The pivotal movement of the lever 75 about theconnection point 100 is limited to an angle, A, of between, for example,zero and approximately 90 degrees. In some embodiments, the pivotalmovement is between approximately zero degrees and approximately 45degrees. In response to contact from the lever 75, the push rod 90 ismoved downward through an aperture 110 (FIG. 3). In some embodiments,the lever 75 also includes legs 115 which extend from the first end 80,and work in conjunction with the housing 55 to limit the pivotalmovement of the lever 75.

As shown in FIGS. 3 and 4, electrical connections to the battery pack 50are made through an interface 120, which is slightly recessed within thehousing 55. Electrical connectors 125 and 130 are located on a bottomside 135 of the housing 55 and are adjacent to a supporting structure,which protects the electrical connectors 125 and 130 within theinterface 120.

FIGS. 7-10 illustrate the battery pack 50 with the housing 55 removed.The battery pack 50 includes one or more battery cells 140 positionedwithin the housing 55. The push rod 90 is movable between a firstposition (e.g., a retracted position) and a second position (e.g., aprotruded position). While in the retracted position, the push rod 90 isretracted within the housing 55. While in the protruded position, thepush rod 90 extends from the housing 55 through the aperture 110. Whenthe push rod 90 is extended through the aperture 110, the force of thepush rod 90 extending through the aperture 110 assists in the removal ofthe battery pack 50 from a device.

A biasing element, such as a spring 145, biases the push rod 90 towardthe retracted position. When the first end 80 of the lever 75 is pulled,the push rod 90 is driven downward against the biasing force of thespring 145 to move the latch 95 from the latched position to theunlatched position. When the lever 75 is moved through a sufficientangular distance, the latch 95 is moved from the latched position to theunlatched position, and the push rod 90 is moved from the retractedposition to the protruded position.

The movement of the push rod 90 occurs along a first axis 150, andmovement of the latch 95 between the latched position and the unlatchedposition occurs along a second axis 155. In some embodiments, the secondaxis 155 is oriented approximately normal to the first axis 150. Thepush rod 90 and the latch 95 are then connected to, coupled to, or incontact with one another in a manner such that a movement of the pushrod 90 along the first axis 150 is translated to a movement of the latch95 along the second axis 155. In one embodiment, the push rod 90includes a tapered portion 160 which engages a tapered portion of thelatch 95 upon movement of the push rod 90.

To secure the battery pack 50 to a device, the latch 95 is biased intothe latched position by a biasing element, such as the spring 165. Themovement of the push rod 90 forces the latch 95 into the unlatchedposition by overcoming the biasing force from the biasing element 165.For example, the push rod 90 causes the latch 95 to move into theunlatched position from the latched position when the push rod 90 ismoved a sufficient distance (e.g., when the lever 75 is pivotally movedthrough a sufficient angular distance). Additionally or alternatively,inserting the battery pack 50 into a device forces the latch 95 againstthe biasing element 165 and into the unlatched position. The latch 95returns to the latched position when the battery pack 50 is fullyinserted into the device.

The battery cells 140 are electrically connected in series and arephysically connected such that the cells 140 are parallel to one anotherand aligned in a single row. In other embodiments, one or moreadditional series-connected groups of battery cells are connected inparallel with the battery cells 140. The interface 120 is also alignedwith the cells 140 at the bottom side 135 of the housing 55 (e.g., asmall end of the housing 55). Such an arrangement of the battery cells140 and the interface 120 allows the heat generated by the cells 140 tobe evenly distributed across the battery pack 50. The battery pack 50 isinserted into a recess of a device with the bottom side 135 of thehousing 55 first, and in some embodiments, more than half of a volume ofthe battery pack 50 is inserted into the recess.

A process 200 for removing the battery pack 50 from a device isillustrated in FIG. 11. The process 200 includes applying a force to thefirst end 80 of the lever 75 (step 205). The force applied to the lever75 causes the lever 75 to pivot about a connection point 100 (step 210)and the second end 105 to engage the push rod 90 (step 215). Thepivoting of the lever 75 is translated into a movement of the push rod90 along the first axis 150 (step 220) following engagement with thesecond end 105 of the lever 75. The movement of the push rod 90 causesthe latch 95 to move against the biasing force of the biasing element165 and move from the latched position to the unlatched position alongthe second axis 155 (step 225). Once in the unlatched position, thelatch 95 allows the battery pack 50 to be removed from the device (step230).

As previously described, the battery pack 50 is configured to be coupledto any of a plurality of devices, such as the devices illustrated in thecleaning system 10 of FIG. 1. The battery charger 30 is illustrated inFIG. 12 and includes a charging base 300 which receives the battery pack50 in a recess 305. Electrical connectors 310 connect the batterycharger 30 to the battery pack 50. FIG. 13 illustrates the battery pack50 coupled to the battery charger 30. The battery charger 30 receivespower from, for example, an AC or a DC voltage source via a power cord315. The battery charger 30 converts the received power to a DC powerlevel suitable for charging the battery pack 50. In some embodiments,the battery pack 50 has a run-time to charge-time ratio such that adevice being powered by the battery pack 50 is able to operate for atleast four minutes for every one hour of charging. In other embodiments,different run-time to charge-time ratios are provided.

The battery charger also includes an LED indicator 320. The LEDindicator 320 provides information to a user related to the state of thebattery charger 30 and the battery pack 50. For example, if the LEDindicator 320 flashes twice followed by a one second off period, thebattery pack 50 is either too hot or too cold. If the LED indicator 320flashes continuously, the battery charger 30 has detected an errorcondition, or there is internal component damage to the battery pack 50or battery charger 30. If the LED indicator 320 remains illuminatedafter a battery pack 50 is removed, the battery charger 30 either needsa reset, or there is internal component damage to the battery charger30. When the LED indicator 320 is continuously lit, the battery pack 50is charging, and if the LED indicator 320 pulses as it gradually dimsand brightens, the battery pack 50 is fully charged.

FIG. 14 illustrates a charging circuit 400 for the battery charger 30.The circuit 400 includes a device controller 405, apulse-width-modulation (“PWM”) module 410, a power supply module 415, asingle ended primary inductor converter (“SEPIC”) module 420, a firstcurrent feedback scaling module 425, a second current feedback scalingmodule 430, and a charge output module 435. The battery charger circuitalso includes one or more LEDs for indicating the battery charger'sstatus, as previously described. In other embodiments, other devices(e.g., vacuums) include features similar to those described below withrespect to the battery charger.

The controller 405 includes, among other things, a processing unit(e.g., a microprocessor, etc.), memory, and a bus. The bus connectsvarious controller components (such as the memory) to the processingunit. In one embodiment, the memory includes read-only memory (“ROM”),random access memory (“RAM”), electrically-erasable programmableread-only memory (“EEPROM”), or flash memory. The controller 405 alsoincludes input/output interfaces and software that includes routines fortransferring information between components within the controller 405.In other embodiments, the controller 405 includes additional, fewer, ordifferent components. The controller 405 is also configured tocommunicate with other components or subsystems within the batterycharger 30 using a bus or other communication interface. In someembodiments, a microcontroller that includes a memory and a bus is usedin place of the controller 405.

The controller 405 is configured to generate a charge current demandsignal. The controller 405 sends the charge current demand signal to thePWM module 410, and the PWM module 410 generates a PWM signal based onthe charge current demand signal. The PWM signal is sent from the PWMmodule 410 to a current source such as the SEPIC converter module 420.The SEPIC converter module 420 is configured to provide a variablevoltage and current source to charge the battery pack 50. The SEPICconverter module 420 includes, among other things, an oscillator, apower FET configured as a switching element, and additional supportcircuits. The current provided by the SEPIC converter module 420 isbased on an analog voltage derived from the charge current demand signaland a low pass filter network (not shown). The SEPIC converter module420 also includes two over-voltage shutdown inputs. A first over-voltageshutdown input is controlled by the controller 405, and a secondover-voltage shutdown input is controlled by a comparator circuit thatoperates independently of the controller 405. The SEPIC converter module420 provides first and second signals representative of the batterycharging current to the first and the second current feedback scalingmodules 425 and 430. Each of the first and second current feedbackscaling modules 425 and 430 includes a single range of operation. Norange selection signal is needed for the current feedback scalingmodules 425 and 430 to properly provide feedback signals to thecomponents of the battery charger 30.

The first current feedback scaling module 425 provides a first feedbacksignal to the PWM module 410. The PWM module 410 uses the first feedbacksignal to adjust the PWM signal to the SEPIC converter module 420 toprovide a current that accurately corresponds to the charge currentdemand signal. The second current feedback scaling module 430 provides asecond feedback signal to the controller 405. The controller 405 usesthe second feedback signal to verify that the current flowing to thebattery pack corresponds to the charge current demand signal. In someembodiments, the controller 405 adjusts the charge current demand signalin response to the second feedback signal.

The battery charger 30 is configured to monitor its output voltage andoutput current. If the output current exceeds a predetermined outputcurrent limit, the battery charger 30 turns off the SEPIC convertermodule 420 to interrupt the output current from the power terminals. Ifthe voltage exceeds a predetermined output voltage limit, the batterycharger 30 turns off the SEPIC converter module 420 to remove voltagefrom the power terminals.

The power supply module 415 supplies a nominal 18V DC voltage to thebattery charger 30. The power supply module 415 is powered by mainspower with nominal line voltages between, for example, 100V and 240V ACand frequencies of approximately 50-60 Hz. The power supply module 415is also configured to supply lower voltages to operate circuits andcomponents within the battery charger 30.

FIG. 15 illustrates a control circuit 500 for a battery pack, such asthe battery pack 50. The control circuit 500 includes a cell assembly505, a battery pack controller 510, a charge control module 515, and adischarge control module 520. The battery pack also includes a firstpower terminal 525, a second power terminal 530, a serial data line(“SDL”) or communication terminal 535, and a product interface 540A. Inother embodiments of the invention, the battery pack includes aplurality of additional power and/or communication terminals (e.g.,multiple positive terminals). In some embodiments, the battery pack isconfigured to provide discharge currents between 7 and 11 Amps and canaccommodate in-rush currents of between 60 and 70 Amps. In otherembodiments, the battery pack is configured to provide and accommodatedifferent current ranges. The battery pack is configured to connect to adevice that includes, for example, a battery pack interface 540B, adevice controller 545, a motor 550, and a power switch 555.

As illustrated in FIG. 16, the battery pack controller 510 includes aprocessor or processing unit (e.g., a microprocessor, etc.) 560, aserial data line conditioning module 565, a cell voltage feedbackconditioning module 570, a cell discharge equalization module 575, apower supply module 580, a precision voltage reference module 585, acell temperature conditioning module 590, a memory 595, and one or morebusses for interconnecting the components and modules within thecontroller 510. The busses connect the various modules and controllercomponents to the processing unit 560. In one embodiment, the memory 595includes read-only memory (“ROM”), random access memory (“RAM”),electrically-erasable programmable read-only memory (“EEPROM”), or flashmemory. The controller 510 also includes input/output interfaces andsoftware that includes routines for transferring information betweencomponents within the controller 510. In other embodiments, thecontroller 510 includes additional, fewer, or different components. Thecontroller 510 is also configured to communicate with other componentsor subsystems within the battery pack using busses or anothercommunication interface. Software included in the implementation of thebattery pack is stored in the memory 595 of the controller 510. Thesoftware includes, for example, firmware, one or more applications,program data, and other program modules. In some embodiments, amicrocontroller that includes a memory and a bus is used in place of thecontroller 510. Although the controller 510 is illustrated as includinga plurality of additional modules, in other embodiments, one or more ofthe modules 565-595 are separate from and connected to the controller510. The power supply module 580 is configured to provide a regulated DCvoltage to the battery pack.

The battery pack controller 510 is configured to communicate with adevice (e.g., a battery charger, a vacuum, etc.), measure the voltage ofeach cell in a cell assembly, measure the discharge current of the pack,control a plurality of field-effect-transistor (“FET”) switches, measurethe temperature of the cell assembly, and monitor the number of chargeor discharge cycles. The battery pack communicates with the device viathe SDL 535. The SDL is coupled to the serial data line conditioningmodule 565 to condition the data transmitted and received by the batterypack. Each device that is connectable to the battery pack is capable ofinterrupting the SDL connection to the battery pack to reduce leakagecurrent experienced by the battery pack if the battery pack remainsconnected to the device for an extended period of time while in thesleep mode.

Executable instructions stored within the memory 595 of the controller510 are configured to maintain a count (e.g., a 16-bit count) thatrepresents the number of charge or discharge cycles experienced by thebattery pack. Additionally or alternatively, the instructions areconfigured to maintain a first count and a second count (e.g., first andsecond 16-bit counts). A first count records charge cycles and thesecond count records discharge cycles. The charge/discharge counts areincremented each time the battery pack successfully enters a normaldischarge or normal charge mode (described below). The counts are storedin the memory 595 of the battery pack controller 510.

The battery pack controller 510 is also configured to store chargeand/or discharge operating parameters, cell identification information,and current charge capacity information in the memory 595. The batterypack provides the charge and/or discharge operating parameters to abattery charger, a configuration device, or a cleaning device. Theoperating parameters include, for example, a voltage rating of thebattery pack, a manufacturer of the battery pack, a model number foreach of the cells in the battery pack cell assembly, a voltage rating ormeasurement for each cell in the cell assembly, a cell temperaturerating or measurement for each cell in the cell assembly, a data tablefor correlating cell voltage values with discharge current values, andthe like. In other embodiments, more or different parameters areprovided to the battery charger, configuration device, or cleaningdevice.

The battery pack uses the charge and/or discharge operating parametersto, among other things, provide a device fuel gauge with an accuratecharge capacity estimation. The fuel gauge is universal in that it doesnot have to be modified or calibrated for a device's expected dischargecurrent. As such, a fuel gauge within a device that requires 15 A ofdischarge current can also accurately display the charge capacity of abattery pack in a device that requires 5 A of discharge current. Forexample, when the battery pack is inserted into a device, the batterypack controller 510 is configured to communicate with the fuel gaugewithin the device via the SDL. The battery pack controller 510 includesa table that is used to correlate a cell voltage at a particulardischarge current to a remaining charge capacity of the battery pack.

The battery pack continuously monitors and measures its dischargecurrent to identify a portion of the table to use to determine theremaining charge capacity of the battery pack. The voltage of each cellwithin the battery pack is then measured. The lowest measured cellvoltage is used as a pointer in the table. The battery pack uses thelowest battery cell voltage measurement and a discharge currentmeasurement to determine an estimated battery capacity for the batterypack based on the identification and operating parameter informationstored in memory. The battery pack controller 510 transfers the chargecapacity information to the fuel gauge (e.g., to a fuel gauge controlleror display device). For example, the estimated battery capacity istransmitted as a 2-bit code that has four possible capacity levels. Inother embodiments of the invention, more bits can be used to increasethe accuracy of the battery capacity estimation displayed on the fuelgauge.

The fuel gauge displays the charge capacity of the battery pack withouthaving to perform calculations or measure voltages. In some embodiments,the fuel gauge includes three LEDs. When all three LEDs are in anilluminated state, the battery capacity is greater than or equal to 75%.When two LEDs are in an illuminated state, the battery capacity isgreater than or equal to 50%. When one LED is in an illuminated state,the battery capacity is greater than or equal to 25%. If a single LED isblinking, the battery capacity is less than 25%. In other embodiments,more or fewer LEDs are used, and the LEDs display different batterycapacity ranges. Devices that include a fuel gauge are also able to usethe characteristics of the cells in the cell assembly to adjust theoperation of the fuel gauge, such that the fuel gauge more accuratelyrepresents the charge capacity of the battery pack.

Additionally or alternatively, the devices are configured to communicatewith the battery pack to adjust other operations based on the operatingparameters of the battery pack and cells. For example, if the voltage ofone of the battery cells falls below a predetermined low voltage limit,the battery pack turns off the charge control module 515 and thedischarge control module 520 to terminate the discharge currentregardless of the logic level of the SDL or the presence of validcommunication with the device controller 545. In some embodiments, thedevice terminates operation, prohibits features, or reconfigures itselfto operate at a different voltage based on the information from thebattery pack.

Because the battery pack provides information to the device to which itis connected, the battery charger 30 can be used to charge a variety ofdifferent battery packs without requiring a user to specify the batterypack voltage. The battery charger 30 adjusts, for example, chargingcurrents, charging voltages, and cut-off thresholds to accommodatemanufacturer's specifications for each cell in the cell assembly. Byadjusting charge and discharge parameters for each cell in the cellassembly, the life and performance of the battery pack can be improvedand errors relating to incorrect charging and/or discharging parameterscan be reduced or eliminated.

The cell voltage feedback conditioning module 570 is configured toattenuate and condition the voltages from each cell in the cell assembly505 to a level that is within the measurement range of the battery packcontroller 510's analog-to-digital converter (“ADC”). The cell voltagefeedback conditioning module 570 is activated by the battery packcontroller 510 when the voltage of a cell is being measured, and isturned off by the battery pack controller 510 when cell voltages are notbeing measured to prevent unnecessary cell discharge. The cell dischargeequalization module 575 is configured to apply a nominally equal load toeach cell in the cell assembly 505 to prevent an imbalance in batterycell discharge. The cell discharge equalization module 575 is turned onand off at the same time as the cell voltage feedback conditioningmodule 570.

The precision voltage reference module 585 is configured to provide aprecise reference voltage to the controller 510's ADC. The voltagereference is used by the ADC to measure signals within the battery pack.The precision voltage reference module 585 is activated by the batterypack controller 510 when the ADC is taking a measurement. The celltemperature conditioning module 590 is configured to measure thetemperature of the cells in the cell assembly using, for example, athermistor. In some embodiments, the thermistor is thermally coupled tothe cells using a thermally conductive gel.

The charge control module 515 is configured to control when the cellassembly 505 is charged. The charge control module 515 includes at leastone FET which is configured as a switch and is controlled by the batterypack controller 510. If the FET is “on,” the cell assembly 505 can becharged. If the FET is “off,” the cell assembly 505 cannot be charged.The discharge control module 520 includes at least one FET configured asa switch to control current discharge from the cell assembly 505. If theFET is “on,” the cell assembly 505 can be discharged. If the FET is“off,” the cell assembly 505 cannot be discharged. The discharge controlmodule 520 is controlled by the battery pack controller 510.

A process 600 for switching the battery pack between a “sleep” mode anda “wake” mode is illustrated in FIGS. 17 and 18. In addition to being alow-power mode for the battery pack, the sleep mode also provides safetybenefits to the battery pack and its users. For example, while in thesleep mode, the battery pack is unable to supply any significant amountof power to an external device or its power terminals (e.g., currents inthe micro-ampere range). As such, the risk of, for example,short-circuited power terminals causing a fire or similar safety concernis eliminated or significantly reduced. The battery pack enters thesleep mode (step 605) when it is not inserted in the battery charger ora cleaning device, as described below. During the sleep mode, thedischarge control module 520 is turned off (step 610) and the chargecontrol module 515 is turned off (step 615) to prevent the battery packfrom sourcing any significant current between a positive terminal and anegative terminal of the battery pack. Turning off the charge controlmodule 515 and the discharge control module 520 also removes the groundpath for the battery cells contained within the battery pack and removesthe voltage from the power terminals. Turning off the charge controlmodule 515 and the discharge control module 520 also prevents thebattery pack from supplying power to an external load, being charged bythe battery charger 30, or being short-circuited. With the ground pathremoved, no devices are able to communicate with the battery packcontroller 510 because there is no common ground reference. In someembodiments, a small signal-level current can flow between the positiveterminal and the SDL when the battery pack is in the sleep mode. A sleeptimer is then set (step 620). Hardware within the battery packcontroller continuously monitors the SDL (step 625). If a high logiclevel (e.g., a high TTL level) is applied to the SDL, the hardwareinterrupts the battery pack controller 510, and the controller 510enters the wake mode (step 630) (FIG. 18). Otherwise, the controller 510remains in the sleep mode.

While in the sleep mode, the battery pack controller 510 is configuredto compare the sleep timer to a limit (e.g., 60-120 minutes) (step 635).The battery pack wakes up (step 640) when the sleep timer is equal tothe limit. The battery pack performs a cell voltage check (step 645) todetermine (step 650) whether the battery pack's cell assembly chargelevel has fallen to a level or below a threshold that prohibitsdischarge. If the battery pack determines that one or more of its cellshave fallen below the minimum allowable level, the battery pack sets asoftware flag to prevent discharge (step 655) and the battery packre-enters the sleep mode (step 605). The battery pack removes thesoftware flag after the battery pack has been connected to the batterycharger 30. If the cells have not fallen below the minimum allowablelevel, the battery pack is configured to re-enter the sleep mode (step605). In some embodiments, the battery pack is configured to disconnecta positive terminal of the cell assembly to remove voltage from thepower terminals, and additional or different hardware is used to switchbetween the sleep and wake modes. In some embodiments, various stepsdescribed above are combined into a single step, or the steps areexecuted in a different order. For example, in one alternativeembodiment, the sleep mode is entered when the sleep timer is set.

The wake mode and wake-up procedure described herein areinterrupt-driven. As such, the battery pack enters the wake mode withouthaving to wait for a predefined time period or for the battery packcontroller 510 to poll the SDL. If the battery pack is connected to adevice with its power switch turned on, the device connects the batterypack's SDL to the battery pack's positive power terminal via a resistornetwork, and the battery pack's SDL is pulled high (e.g., pulled to alogical high level). When the battery pack controller 510 determinesthat a high logic level is applied to the SDL, the battery pack entersthe wake mode (step 630). The battery pack controller 510 then debouncesthe SDL and verifies whether the battery pack is connected to a devicewith its power switch turned on (step 660). The battery pack controller510 debounces the SDL for a predetermined period of time (e.g., 60 ms)to ensure that the voltage at the SDL was not a result of a noise spike.

If the battery pack is not connected to a device or the device's powerswitch is not turned on, the battery pack re-enters the sleep mode (step605). If the battery pack controller 510 determines that the logic levelpresent at the SDL is the result of a connection between the batterypack and a device with its power switch turned on, the battery packenters a normal discharge mode (“NDM”) (step 665) and activates or turnson the discharge control module 520 (step 670) and the charge controlmodule 515 (step 675). Activating the discharge control module 520 andthe charge control module 515 provides a common ground reference betweenthe battery pack and the device, and power to the positive and negativepower terminals. Communication between the battery pack and the deviceis then able to begin. The battery pack is configured to establishcommunication (step 680) with the device controller 545 via the SDL. Thebattery pack then determines whether communication has been established(step 685). If communication is not established, the battery packre-enters the sleep mode (step 605). If communication is established,the battery determines whether the device is a battery charger (step690). If the device is a battery charger, the battery pack enters anormal charge mode (“NCM”) (step 695). If the device is not a batterycharger, the battery pack continues to operate in the normal dischargemode (step 700).

In other embodiments of the invention, the battery pack is configured todisconnect a positive terminal of the cell assembly 505 (e.g., turn offat least one FET) when the battery pack is in the sleep mode. When thebattery pack is inserted into a device, the device connects the SDL tothe battery pack's negative terminal to provide a logical low level tothe SDL when the device power switch 555 is turned on. The SDL isconnected to the negative terminal using a resistor network within thedevice. The battery pack is configured to communicate with the deviceand debounce the SDL as described above. If, after debouncing, the logiclevel of the SDL meets predetermined conditions for a low logic level,the battery pack controller 510 turns on the charge and dischargecontrol modules to supply current to or receive current from the device.

The battery pack is also configured to transmit multi-byte messages tothe device on the SDL. The device is configured to receive the messageson the SDL and respond with a message to the battery pack controller 510related to, for example, the condition of the battery pack (e.g.,charging mode, discharging mode, etc.). The battery pack controller 510periodically polls the device controller 545 to verify presence andproper function. For example, the battery pack controller 510 sends fivemessages over the SDL during a period of one second to initiatecommunication with the device. If the battery pack controller 510 doesnot receive an expected response or a valid message from the devicecontroller 545 during this time period, the battery pack controller 510turns off the charge and discharge control modules 515 and 520, andenters the sleep mode regardless of the logic level of the SDL. Turningoff the charge and discharge control modules 515 and 520 removes theground path for the cell assembly 505 to stop the supply of power to thedevice.

Additionally or alternatively, if the battery pack and the device failto successfully maintain communication, the battery pack controller 510turns off the charge and discharge control modules 515 and 520 andenters the sleep mode. For example, the battery pack controller sends amessage to the device controller approximately once per second. If thebattery pack controller does not receive a valid response to thismessage within a certain number of communication cycles (e.g., threecommunication cycles), the battery pack controller 510 turns off thecharge and discharge control modules 515 and 520 and enters the sleepmode. In other embodiments, the battery pack is configured to disconnectthe positive terminal of the cell assembly to stop the supply of powerto the device, and the battery pack enters the sleep mode. If thebattery pack receives a valid response from the device, the battery packremains in the wake mode. While in the wake mode, the charge anddischarge control modules 515 and 520 remain on, the battery packprovides a connection to the positive terminal of the cell assembly toprovide power to the battery pack's power terminals, and the batterypack is able to power a device or be charged by the battery charger 30.

The wake mode includes the NDM and the NCM. If the battery pack isconnected to a device, is in communication with the device via the SDL,and has determined that the device is not a battery charger, the batterypack is configured to operate in the NDM. When in the NDM, the batterypack verifies that the voltages and temperatures of its cells are withinpredetermined operational limits. If the battery pack sends a message tothe device and receives a valid response on the SDL, the battery packcontinues to supply power through the power terminals. If the batterypack does not receive a valid response through the SDL for apredetermined number of communication cycles, the battery pack turns offthe charge control module 515 and discharge control module 520 andenters the sleep mode.

When operating in the NDM, the battery pack also continuously monitors adischarge current from its power terminals. If the discharge current isnot within predetermined operational limits for current discharge versustime, the battery pack turns off the charge control module 515 and thedischarge control module 520 to terminate the discharge current andenters the sleep mode regardless of the logic level of the SDL or thepresence of valid communication with the device controller 545.

The battery pack also monitors the temperature of the battery cells inthe cell assembly 505. In order to compensate for thermal lag in thebattery pack's temperature measurement system, the battery pack appliesa temperature correction factor using an index value based on thedischarge current. The correction factor is only used if the measuredcell temperature is above 25° C. If the corrected temperaturemeasurement is not within predetermined operational temperature limits,the battery pack turns off the charge control module 515 and thedischarge control module 520 to terminate the discharge current andenters the sleep mode regardless of the logic level of the SDL or thepresence of valid communication with the device controller 545.

When the battery pack is discharging current, the battery packcontinuously communicates with the device. For example, the battery packcontroller 510 initiates and controls communication with the device. Inother embodiments, the device controls communication with the batterypack (e.g., the device functions as a master device and the battery packfunctions as a slave device). If the device fails to respond to thebattery pack for the predetermined number of consecutive communicationcycles (e.g., three cycles), the battery pack turns off the chargecontrol module 515 and the discharge control module 520 to terminate thedischarge current and then returns to the sleep mode.

Additionally, when the battery pack is discharging current, the batterypack also continuously monitors the voltage of each of the batterycells. If the voltage of one of the battery cells falls below apredetermined low voltage limit, the battery pack turns off the chargecontrol module 515 and the discharge control module 520 to terminate thedischarge current and then enters the sleep mode regardless of the logiclevel of the SDL or the presence of valid communication with the devicecontroller 545.

When the battery pack terminates a current discharge process, thebattery pack transmits a termination message to the device on the SDLthat indicates why the current discharge process is being terminated.The battery pack transmits the termination message unless, for example,an over-current condition occurs during discharge which requiresdischarge current to be terminated in a period of time that precludesthe battery pack from transmitting the termination message.

Additionally, if the battery pack enters the NDM as a result of beingcoupled to a configuration device, a special set of operating parametersare enabled. Configuration devices have the ability to request that thebattery pack read and/or write values from individual memory locations(e.g., non-volatile memory locations) within the battery pack's memory595. Such an ability is particularly beneficial for devices which areassembled at multiple locations, or devices which have components thatare manufactured at one or more locations but are assembled at anotherlocation. The ability to adjust operating parameters enables uniformoperation of each of the devices, allows for the access ofcharge/discharge information stored within the memory, and allows forthe modification of, for example, cell-specific charging parameters. Theconfiguration device is a dedicated device or is incorporated into adevice such as the battery charger 30 or a cleaning device. Theconfiguration device includes a user interface that is configured todisplay operating parameters of the battery pack and allow a user toadjust the operating parameters of the battery pack. The configurationdevice is configured to request that the battery pack provide specificoperating parameters or the contents of a specific memory location. Theconfiguration device is also configured to request that the battery packadjust a specific operating parameter or the value of a specific memorylocation to a value provided by the configuration device. For example,calibration data stored within the battery pack's memory can be read ormodified, or the charge/discharge cycle count data can be retrieved. Inother embodiments, the configuration device is configured to verify thatthe value of a memory location has been adjusted by requesting that thebattery pack provide the adjusted memory value to the configurationdevice.

If the configuration device requests information from the battery pack,the battery pack remains as the master device during communications. Thebattery pack initiates communications with the configuration device, andthe configuration device responds to the communications from the batterypack. If the configuration device requests that the battery pack providethe value of a particular memory location, the battery pack complies butresponds to the request on the next communication cycle. In someembodiments, the configuration device initiates communication with thebattery pack.

When the battery pack is operating in the NCM, the battery pack controlsthe charging operations. However, the battery charger 30 does notcompletely relinquish charging control to the battery pack. For example,the battery charger determines whether to terminate a constant-voltagecharge during a charging process. The battery pack stores cell-specificcharge parameters in its non-volatile memory and provides chargingprocess information to the battery charger 30 for use during thecharging process. When the battery pack is receiving a charging current,the battery pack continuously communicates with the battery charger 30.If the battery charger 30 fails to receive messages from the batterypack for the predetermined number of communication cycles, the batterycharger 30 turns off the SEPIC converter module 420 and removes voltagefrom the charging terminals.

The battery pack measures the voltage of each of the cells in the cellassembly 505 during the NCM. When one of the cells within the cellassembly 505 reaches a specified cut-off voltage, the battery packrequests that the battery charger 30 enter a constant-voltage chargemode. After the battery charger receives the request to enter theconstant-voltage charge mode, the charging process is controlled by thebattery charger 30.

While in the constant-voltage charge mode, the battery charger 30provides a constant voltage to the terminals of the battery pack andmonitors the charge current. If the charge current falls to apredetermined limit, the battery charger 30 terminates the chargingprocess, and the battery pack turns off the charge control module 515and the discharge control module 520 to terminate the charging currentand enters the sleep mode.

While in either the constant-voltage charge mode or the constant-currentcharge mode, the battery pack also measures the temperatures of thecells within the cell assembly. Based on the battery cell temperatures,the battery pack requests normal charge parameters (i.e., NCMparameters), or reduced current charge parameters, or turns off thecharge and discharge control modules 515 and 520 to terminate thecharging current temporarily until temperatures of the battery cellsreturn to predetermined operational limits. If the battery packindicates to the battery charger 30 (e.g., via the SDL) that a celltemperature within the battery pack cell assembly is outside of apredetermined temperature range, the battery charger 30 turns on the LEDindicator as previously described and waits for the cell temperatures tonormalize and the battery pack to again request the charging current.

Depending on the charging mode (e.g., constant-current orconstant-voltage charging mode), a plurality of redundant checks areperformed by either the battery pack or the battery charger 30 while theother is controlling the charging process. During the NCM, the batterycharger 30 monitors the overall pack voltage and controls switching fromthe constant-current charging mode to the constant-voltage charging modeif the battery pack does not request a change in charging modes, and thebattery pack voltage is within the predetermined voltage limits for theconstant-voltage charging mode. Similarly, during constant-voltagecharging mode, the battery pack monitors battery cell voltages and theoverall pack voltage. If either the cell voltages or overall packvoltage satisfies predetermined limits for the battery pack being fullycharged, the battery pack turns off the charge and discharge controlmodules 515 and 520 to terminate the charging current and enters thesleep mode.

The battery pack and battery charger 30 also include charge timers. Bothof the charge timers are operational any time that a battery pack isbeing charged, including idle periods when battery cell temperaturestemporarily prohibit further charging. If the battery pack charge timerexceeds a predetermined time limit, the battery pack turns off thecharge and discharge control modules 515 and 520 to terminate thecharging current and enters the sleep mode. Additionally oralternatively, if the battery charger charge timer exceeds apredetermined time limit, the battery charger 30 transmits a message tothe battery pack and turns off the SEPIC converter module 420 to removevoltage. The battery charger 30 is also configured to turn the LEDindicator 320 on and off to indicate the time-out condition. When thebattery pack terminates a charging process, the battery pack transmits atermination message to the battery charger 30 on the SDL that indicateswhy the charging process is being terminated.

As previously described, the battery pack 50 is configured to be coupledto any of a plurality of devices. FIGS. 19-23 illustrate an electricallypowered cleaning device, such as a stick-type vacuum 20 which receivespower from the battery pack 50. In some embodiments, the vacuum cleaner20 and the battery pack 50 have a combined weight of less thanapproximately 7.5 pounds. The vacuum cleaner 20 includes a handleportion 805, a body portion 810, and a base or nozzle base portion 815.In some embodiments, the vacuum cleaner 20 includes a hose or otherattachments.

The handle portion 805 includes a first section 820 and a second section825. The first section 820 is oblique with respect to the second section825 and includes a grip portion 830 (FIG. 21). The grip portion 830 ison an opposite side of the first section 820 as a power switch orselection device 835. In some embodiments, the grip portion 830 extendscompletely or almost completely around the first section 820. The firstsection 820 of the handle portion 805 also includes a capacitive touchsensor for determining whether a user is touching the handle portion805. If the user is touching the handle portion 805, the vacuum cleaner20 operates as selected using the power switch 835. If the user is nottouching the handle portion 805, the vacuum cleaner 20 reduces the speedof a motor/fan assembly 840. By reducing the speed of the motor/fanassembly 840 (e.g., by reducing the current provided to the motor/fanassembly 840), the vacuum cleaner 20 is able to conserve power when theuser is away from the vacuum cleaner 20.

The second section 825 of the handle portion 805 includes, among otherthings, a plurality of indicators 845 for providing indications to auser related to the operational mode of the vacuum cleaner 20. In someembodiments, the handle portion 805 includes a first LED indicator and asecond LED indicator. The first LED indicator provides an indication toa user related to whether suction is active for the vacuum cleaner 20.The second LED indicator provides an indication to the user related towhether suction and a brush roll are active for the vacuum cleaner 20.When the vacuum cleaner 20 is off or in an inactive state, neither thefirst nor the second LED indicators is in an illuminated state. When thevacuum cleaner 20 is in a suction only operational mode, the first LEDindicator is in an illuminated state. When the vacuum cleaner 20 is in asuction and brush roll operational mode, the second LED indicator is inan illuminated state. The operational mode of the vacuum cleaner 20 isset by the power switch 835, which is manipulable by a finger of a userwhile grasping the first section 820 of the handle portion 805. In someembodiments, the switch 835 is rolled by a user into a plurality ofpositions corresponding to operational modes of the vacuum cleaner 20.

In some embodiments, the handle portion 805 is removably coupled to thebody portion 810. For example, for storage or transport purposes, thehandle portion 805 is detachable from the body portion 810. In suchembodiments, the handle portion 805 is coupled and secured to the bodyportion 810 via friction only. In other embodiments, a screw or othersuitable fastening device is used to secure the handle portion 805 tothe body portion 810. As shown in FIG. 24, the handle portion 805 alsoincludes a plurality of electrical connectors 850 located at aninterface 855 between the handle portion 805 and the body portion 810.The electrical connectors 850 connect the handle portion 805 to the bodyportion 810 such that electrical signals related to the operation of thevacuum cleaner 20 are provided to the body portion 810 to control, forexample, the motor/fan assembly 840.

The body portion 810 includes a recess 860, a fuel gauge 865, themotor/fan assembly 840, and a refuse chamber 870. In some embodiments,the body portion 810 also includes a cyclonic separator. The recess 860is shaped and configured to receive the battery pack 50, and ispositioned along a centerline or axis (e.g., a first axis as describedbelow) of the body portion 810. Such a positioning of the recessimproves the balance, steering, and compactness of the vacuum cleaner20. The recess 860 includes a plurality of electrical connectors similarto the electrical connectors 310 shown in FIG. 12 with respect to thebattery charger 30 for electrically connecting the battery pack 50 tothe vacuum cleaner 20. As described above, the fuel gauge 865 isconfigured to provide an indication to the user of the charge level ofthe battery pack 50 inserted into the vacuum cleaner 20. In theillustrated embodiment, the fuel gauge 865 is positioned above therecess 860. The fuel gauge 865 is oblique with respect to the secondsection 825 of the handle portion 805 such that a user is able to readthe fuel gauge 865 during normal operation of the vacuum cleaner 20without having to divert his or her attention from operating the vacuumcleaner 20. In some embodiments, the fuel gauge 865 is located in thebase portion 815 of the vacuum cleaner 20.

The motor/fan assembly 840 is positioned below the battery pack 50 andthe fuel gauge 865. Such an arrangement between the battery pack 50 andthe motor/fan assembly 840 is advantageous because airflow from themotor/fan assembly 840 provides cooling to the battery pack 50 andassociated electronics. In some embodiments, the motor is a verticalbrushless DC motor (“BLDC”). In other embodiments, different types of ACor DC motors are used, such as a brushed DC motor, a stepper motor, asynchronous motor, or other motors which use permanent magnets. In someembodiments, the body portion 810 also includes a diffuser, such as thediffuser disclosed in U.S. Pat. No. 7,163,372, entitled “DIFFUSER FOR AMOTOR FAN ASSEMBLY,” the entire contents of which are herebyincorporated by reference.

The refuse chamber 870 is positioned below the motor/fan assembly 840,and is removably coupled to the body portion 810. In the illustratedembodiment, the refuse chamber 870 is bagless and includes a latchingmechanism 875 (FIG. 25), which secures the refuse chamber 870 to thevacuum cleaner 20. The refuse chamber 870 also includes a lower portionhaving a latch 880 for emptying the contents of the refuse chamber 870and an inlet 885 for receiving refuse.

A lower end of the body portion 810 includes an interface for attachingthe body portion 810 to the base portion 815. The base portion 815includes a corresponding interface (FIG. 26) for attaching to the bodyportion 810. The interface includes, among other things, two terminals890 and 895 for providing power to the base portion 815, and an outlet900 for providing refuse to the body portion 810. The interface betweenthe body portion 810 and the base portion 815 allows the vacuum cleaner20 to stand upright without external support. For example, the vacuumcleaner 20 is operable in an upright working position in which thevacuum cleaner 20 can be operated without a user supporting the handleportion 805 or the body portion 810. The base portion 815 is capable ofbeing detached from the body portion 810 without the use of a tool, suchas a screwdriver.

The base portion 815 also includes a multi-axis pivot joint 905. Inalternative embodiments, a ball joint is employed. The pivot joint 905allows the handle and body portions 805 and 810 of the vacuum cleaner 20to pivot with respect to the base portion 815. For example, the pivotjoint 805 allows for pivotal movement of the handle and body portions805 and 810 about a first axis 910 parallel to a cleaning surface.Pivotal movement about the first axis 910 allows the handle and bodyportions 805 and 810 to be moved from a position approximatelyperpendicular to the base portion 815 to a position approximatelyparallel to the ground. For example, the handle and body portions 805and 810 of the vacuum cleaner 20 are able to be moved through an angleof between approximately 0.0° and approximately 90.0° with respect tothe base. In other embodiments, the handle and body portions 805 and 810are pivotable through larger angles.

The handle and body portions 805 and 810 are also pivotable along asecond axis 915. The second axis 915 is approximately perpendicular tothe first axis 910 and is approximately parallel to both the handle andbody portions 805 and 810 of the vacuum cleaner 20. Pivotal movementabout the second axis 915 provides additional control andmaneuverability of the vacuum cleaner 20. The base portion 815 alsoincludes a first wheel 920 and a second wheel 925 which provide rollingmovement of the vacuum cleaner 20 along a cleaning surface following theapplication of an external force by a user. The first and second wheels920 and 925 are coupled to the base portion 815 along the first axis910. The base portion 815 includes a suction inlet 935 on an undersideof the base portion 815. The suction inlet 935 includes an aperture ornotch 940 which allows larger objects (e.g., cereal and similarly sizedrefuse) to enter the suction inlet 935 without requiring a user to liftthe vacuum cleaner 20. In some embodiments, airflow through the baseportion 815 is preconditioned.

The base portion 815 includes a brush roll motor (not shown) forrotating a brush roll 945. In one embodiment, the base portion 815 isimplemented in a manner similar to that described in U.S. Pat. No.5,513,418, entitled “SUCTION NOZZLE WITH DUCTING,” the entire contentsof which are hereby incorporated by reference. In other embodiments, thebase portion is implemented in a manner similar to that described inU.S. Pat. No. 7,100,234, entitled “SUCTION NOZZLE ASSEMBLY,” the entirecontents of which are also hereby incorporated by reference. The brushroll motor is selectively activated by a user. For example, when theuser selects the suction only operational mode for the vacuum cleaner20, the brush roll motor is in an off state and the brush roll does notrotate. Such an operational mode is often used on cleaning surfaces suchas, for example, hardwood floors. When the user selects the suction andbrush roll mode, the brush roll motor is in an on state and the brushroll rotates. Such an operational mode is often used on carpetedsurfaces. In some embodiments, the vacuum cleaner 20 is configured toprovide at least approximately 6 air Watts of power at the suction inlet935 of the base portion 815.

FIGS. 27-30 illustrate the battery pack 50 coupled to the hand-heldvacuum 15. The hand-held vacuum 15 includes a body 1105, a handle 1110,and a refuse chamber 1115. The body 1105 includes a nozzle 1120, asuction inlet 1125 (FIG. 30), a suction motor/fan assembly 1130, and arecess 1135. The recess 1135 is sized and configured to receive thebattery pack 50. The battery pack 50 couples to and electricallyconnects to the hand-held vacuum 15 in a manner similar to thatdescribed above with respect to the stick-type vacuum 20. The handle1110 is integrated into the body 1105, and is positioned between therecess 1135 and the nozzle 1120. A junction of the handle 1110 and thenozzle 1120 includes a switch 1140 and a fuel gauge 1145. The switch1140 includes, for example, a first position (e.g., an ‘ON’ position)and a second position (e.g., an ‘OFF’ position) for controlling theoperation of the hand-held vacuum 15. In other embodiments, the switch1140 includes additional positions corresponding to additionaloperational modes of the hand-held vacuum 15, such as a high-speedsetting and a low-speed setting for the motor 1130. The fuel gauge 1145of the hand-held vacuum 15 operates in a manner similar to the fuelgauge 865 described above with respect to the stick-type vacuum 20.

In some embodiments, the hand-held vacuum 15 is configured to provide atleast 13 air Watts of power at the suction inlet 1125. The nozzle 1120also includes a crevice/brush tool 1150 coupled to the nozzle 1120. Inthe illustrated embodiment, the crevice/brush tool 1150 is pivotallycoupled to the nozzle 1120. When in a storage position, thecrevice/brush tool 1150 is pivoted to a position clear of the suctioninlet 1125 on an underside of the nozzle 1120. When in a use position,the crevice/brush tool 1150 is pivoted from the storage position suchthat it is substantially in front of the suction inlet 1125. In otherembodiments, the crevice/brush tool 1150 is removably coupled to thenozzle 1120 or another portion of the hand-held vacuum 15. The refusechamber 1115 is positioned between the motor 1130 and the nozzle 1120.The refuse chamber 1115 is, for example, frictionally coupled to thehand-held vacuum 15 or coupled via a latching mechanism. The refusechamber 1115 includes an inlet (not shown) for receiving refuse from thenozzle 1120. In the illustrated embodiment, the refuse chamber 1115 isbagless. In other embodiments, the refuse chamber 1115 includes a bag orsimilar disposable storage accessory.

Although the battery pack 50 has been described primarily with respectto its interconnections and coupling to battery chargers, stick-typevacuums, and hand-held vacuums, the battery pack 50 is configured to becoupled to the other devices in the cleaning system 10 illustrated inFIG. 1. For example, the battery pack 50 is configured to be coupled toand power the bagless upright vacuum 25, the bagged upright vacuum 35,the carpet cleaner 40, and the canister vacuum 45. In some embodiments,one or more of the devices illustrated in FIG. 1 include aheight-adjustable handle or body portion. Additionally, the specificmanner and techniques for connecting the battery pack 50 to thesedevices is not described. However, in some embodiments, theinterconnections between the battery pack 50 and the devices are similarto the interconnections described above with respect to the stick-typevacuum 20 and the hand-held vacuum 15, although specific operatingparameters and characteristics vary among the devices.

In some embodiments of the invention, when the battery pack 50 is notcoupled to the battery charger 30, the battery charger 30 is used toprovide power to additional devices. For example, the battery charger 30is configured to provide power to devices such as those illustrated inFIGS. 31-39. The devices include a night-light 1200, a kitchen timer1205, a clock 1210, an audio storage device dock 1215, an air ionizer,freshener, or fan 1220, an LCD screen 1225, a USB charging station 1230,an indoor weather station 1235, and a mobile phone charger orspeakerphone 1240. In other embodiments, the battery charger 30 isconfigured to charge additional devices. Each of the devices 1200-1240includes terminals similar to those described above with respect to thebattery pack 50 for coupling to the battery charger 30, or an adapter isprovided to connect the devices 1200-1240 to the battery charger 30. Insome embodiments, the battery charger 30 is configured to both power atleast one of the devices 1200-1240 and charge a battery pack 50. In suchembodiments, the battery charger 30 includes either a recess forreceiving a battery pack 50, or the device includes an interface forelectrically connecting the battery pack 50 to the battery charger 30.

Thus, the invention provides, among other things, a cordless,battery-powered system of electronic devices, such as a system ofcleaning products. Each of the devices is powered by a battery packwhich is interchangeable among the devices. Various features andadvantages of the invention are set forth in the following claims.

What is claimed is:
 1. A cordless upright vacuum cleaner, comprising: anozzle base portion having a suction inlet; a body portion; a pivotablejoint coupled between the nozzle base portion and the body portion; asuction source for providing a suction force at the suction inlet; and abattery pack interface configured to receive a removable andrechargeable lithium-based battery pack, the battery pack interfaceincluding a battery pack recess, a first power terminal and a secondpower terminal, the vacuum cleaner configured to receive power from thebattery pack over the first power terminal and the second powerterminal, a communication terminal, the vacuum cleaner configured tocommunicatively connect to the battery pack over the communicationterminal, the battery pack including a battery pack housing, a portionof the battery pack housing being insertable into the battery packrecess, the battery pack being selectively removably coupled to thevacuum cleaner, wherein the suction source is powered by the batterypack, the body portion is pivotable relative to a first axis, the bodyportion is pivotable relative to a second axis, and the body portion issupportable by the nozzle base portion in a vertical position withoutexternal support.
 2. The vacuum cleaner of claim 1, wherein the combinedweight of the vacuum cleaner and the battery pack is less thanapproximately seven and one-half pounds.
 3. The vacuum cleaner of claim1, wherein the battery pack recess is configured to receive anextendable latch of the battery pack.
 4. The vacuum cleaner of claim 1,further comprising a fuel gauge external to the battery pack andconfigured to indicate a status of the battery pack.
 5. The vacuumcleaner of claim 1, wherein the first axis is parallel to a cleaningsurface and the second axis is approximately perpendicular to the firstaxis.
 6. The vacuum cleaner of claim 1, wherein the battery pack ispositioned above the suction source.
 7. The vacuum cleaner of claim 1,wherein the vacuum cleaner includes a refuse chamber.
 8. The vacuumcleaner of claim 7, wherein the battery pack is positioned above therefuse chamber.
 9. The vacuum cleaner of claim 8, wherein the batterypack is positioned above the suction source.
 10. The vacuum cleaner ofclaim 7, wherein the battery pack is positioned above the suctionsource, and the suction source is positioned above the refuse chamber.11. The vacuum cleaner of claim 1, wherein the suction source is abrushless direct current (“BLDC”) motor.
 12. The vacuum cleaner of claim1, wherein the vacuum cleaner is configured to provide at leastapproximately 6 air Watts of power at the suction inlet.
 13. The vacuumcleaner of claim 1, wherein the battery pack includes at least twobattery cells.
 14. The vacuum cleaner of claim 1, wherein the vacuumcleaner is configured to communicate serially with the battery pack. 15.The vacuum cleaner of claim 1, wherein the vacuum cleaner receives asignal over the communication terminal related to a voltage of at leastone of a plurality of battery cells within the battery pack housing. 16.The vacuum cleaner of claim 1, wherein the vacuum cleaner is a canistervacuum cleaner.
 17. The vacuum cleaner of claim 1, wherein the vacuumcleaner is a wet/dry floor cleaner.
 18. The vacuum cleaner of claim 1,wherein the vacuum cleaner is a carpet cleaner.
 19. The vacuum cleanerof claim 1, wherein the battery pack has a voltage between 4V and 48V.20. The vacuum cleaner of claim 19, wherein the battery pack isconfigured to provide discharge currents between approximately 7 Ampsand 11 Amps.